System and method employing a porous container for sealing, baffling or reinforcing

ABSTRACT

There is disclosed a system and method of employing a porous container for sealing, baffling, reinforcing or a combination thereof. According to the method, a porous container having one or more openings is provided. An expandable material is associated with the container and is preferably placed within the container. Thereafter, the expandable material is expanded to contact and adhere to a structure of an article of manufacture (e.g., an automotive vehicle).

CLAIM OF BENEFIT OF FILING DATE

The present application claims the benefit of the filing date of U.S.Provisional Application Ser. No. 60/504,260, filed Sep. 18, 2003, herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to a system and method employinga porous container for sealing, baffling or reinforcing articles ofmanufacture. More particularly, the present invention relates to asystem having a porous container and an expandable material associatedwith the container wherein the system is configured to seal, baffle orreinforce a structure of an automotive vehicle.

BACKGROUND OF THE INVENTION

For many years, industry (e.g., the transportation industry) has beenconcerned with designing systems for sealing, reinforcing or bafflingstructures of articles of manufacture (e.g., automotive vehicles). Suchsystems can include a carrier, an expandable material or both. It isgenerally desirable for such systems to be relatively inexpensive. It isalso typically desirable for such systems to be relatively easy to form.Moreover, it is typically desirable for such systems to be easilyassembled to an article of manufacture such as an automotive vehicle.Thus, the present invention seeks to provide an improved system andmethod for sealing, reinforcing or baffling wherein the system, themethod or both exhibit one or more of the aforementioned desirablecharacteristics or other desirable characteristics.

SUMMARY OF THE INVENTION

Accordingly, there is provided a system for sealing, reinforcing orbaffling and a method for forming and/or using the system. The systemtypically includes a porous container and an expandable materialassociated with the porous container. Preferably, the expandablematerial is located at least partially within the porous container.Typically, the expandable material is placed within the porous containerfor forming a member configured to seal, baffle or reinforce a structure(e.g., a pillar) of an article of manufacture (e.g., an automotivevehicle). The system is formed by placing the member (i.e., thecontainer and expandable material) adjacent the structure (e.g., withina cavity of the structure). Preferably, the expandable material isactivated to expand and travel through one or more openings in theporous container to contact one or more walls of the structure of thearticle of manufacture. In turn, the expandable material cures to attach(e.g., adhesively secure) the container and the expandable material tothe one or more walls of the structure. Advantageously, the expandedmaterial can enhance the structural acoustical properties, sealing andbarrier properties, a combination thereof or the like of the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claims,and drawings, of which the following is a brief description:

FIG. 1 is a perspective view of an exemplary container suitable forforming a system according to the present invention.

FIG. 2 is a perspective view of the container of FIG. 1 filled withpellets of expandable material for forming an exemplary sealing,baffling or reinforcing member in accordance with the present invention.

FIG. 3 is a perspective view of the member of FIG. 2 located in a cavityof a pillar of an automotive vehicle for forming an exemplary system inaccordance with the present invention.

FIG. 4 is a perspective view of the exemplary system of FIG. 3 afterexpansion of the expandable material.

FIG. 4A is a perspective view of an exemplary member being formed inaccordance with the present invention.

FIG. 5A is a perspective view of an alternative exemplary containersuitable for forming a system in accordance with the present invention.

FIG. 5B is a perspective cut-away view of the exemplary container ofFIG. 5A.

FIG. 6A is a perspective view of another alternative exemplary containersuitable for forming a system in accordance with the present invention.

FIG. 6B is a perspective cut-away view of the exemplary container ofFIG. 6A.

FIG. 7. is a perspective view of yet another alternative exemplarymember according to an aspect of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is predicated upon providing an improved systemfor sealing, baffling or reinforcing one or more members of an articleof manufacture. The system has found particular utility for automotivevehicles although it is contemplated that the system may be applied to avariety of articles of manufacture such as airplanes, boats, buildings,furniture or the like.

Accordingly, the system of the present invention typically includes oneor more of the following:

-   -   1) a structure (e.g., a pillar structure) of an article of        manufacture (e.g., an automotive vehicle), the structure        preferably having one or more walls at least partially defining        a cavity;    -   2) a porous container at least partially defining an internal        open space, the porous container having one or more openings for        providing fluid communication between the internal open space        and an environment surrounding the container; and    -   3) an expandable material disposed within the internal open        space of the porous container wherein the container and the        expandable material are located adjacent the structure (e.g.,        within the cavity) such that the expandable material expands to        contact the structure (e.g., the one or more walls defining the        cavity).

Referring to FIGS. 1-4, there is illustrated one exemplary preferredembodiment of a system 10 being formed in accordance with the presentinvention. The system 10 is provided for purposes of illustration of thepresent invention. It is contemplated that alternatives to thecomponents and aspects of the system 10 of FIGS. 1-4 may be employed inthe practice of the present invention. Some of those alternatives aredisclosed below, however, the skilled artisan will appreciate that manyother alternatives may also be employed as well in the practice of thepresent invention.

The system 10 typically includes a porous container. In FIG. 1, there isillustrated an exemplary porous container 12 at least partially definingan internal open space 16. The container 12 includes at least oneopening 20, but preferably include a plurality of openings 20 forproviding fluid communication between the internal open space 16 and anexternal environment surrounding the container 12.

In the particular embodiment shown, the container 12 is configured as abox with a top or first end wall 24, a bottom or second end wall 26 andmultiple (e.g., four) side walls 28 extending between the top wall 24and bottom wall 26. Each of the walls 24-28 is illustrated assubstantially rectangular. The top wall 24 and bottom wall 26 aresubstantially continuous or non-porous and the openings 20 areconfigured as elongated slots extending between side edges or top andbottom edges of the side walls. The top wall 24 is at least partiallyformed by a lid, which can be opened and closed.

The container 12 is shown as being formed of a relatively rigidmaterial. The material is preferably a thermoset or thermoplasticmaterial that is able to withstand temperature experienced duringautomobile manufacture (e.g., painting or coating processes). Onepreferred material is a polymeric material such as a polyamide (e.g.,nylon 6,6). Advantageously, such a material may be processed using avariety of different techniques such as molding (e.g., compressionmolding, injection molding, blow molding, gas injection molding or thelike), extruding or other techniques for forming the container 12.

While the container 12 illustrated is considered to be a preferredcontainer for use in the present invention, it is contemplated that avariety of alternatively configured containers may be employed withinthe scope of the present invention. As an initial matter, the containermay be shaped as desired or needed depending upon the intendedapplication for the container. As an example, the container may bedesigned with angles, shapes, contours or the like, which correspond toangles, shapes, contours or the like of a structure of an article ofmanufacture or cavity thereof that the container is intended to beadjacent or within. Alternatively, the container can be shaped such thatit may be placed adjacent or within a variety of differently shapedmembers or cavities.

As one exemplary alternative embodiment, the container may besubstantially cylindrical with a top wall, a bottom wall and a side wallextending between the top wall and the bottom wall. Preferably, the topand bottom wall are substantially round (e.g., circular, elliptical,oval or the like) and the side wall is substantially annular. Also, itis preferred, although not required, that the top and bottom wall becontinuous or non-porous while the side wall preferably includes one ora plurality of openings (e.g., vertically extending slots).

It is also contemplated that the container may be formed of a variety ofmaterials, which may be flexible, semi-rigid or rigid. As examples, thecontainer may be formed of polymeric materials, metals (e.g., aluminum,steel, magnesium, combinations thereof or the like), fabrics, fibrousmaterials combinations thereof or the like. Exemplary, polymericmaterials (e.g., thermoplastics, rubber, thermosets or the like), whichmay be configured as sheets, fabrics or the like include, withoutlimitation, polyester, polypropylene, polyamide, polyethylene,polyvinylchloride, polyethylene, combinations thereof or the like).

Particularly, for flexible or semi-rigid materials, it is contemplatedthat a portion or the entire container may be formed of flexible wallsto assist in allowing the container to adapt or correspond to walls andcontours of a member of an article of manufacture. In one example, aperforated bag (e.g., a mesh bag) having multiple openings (e.g.,through-holes) is employed as the container. In another example, thecontainer includes a rigid or semi-rigid bottom and/or top wall that aresubstantially continuous or non-porous and a flexible porous material(e.g., a fabric) comprising one or more side walls for the carrier.

In one embodiment, it is desirable for the material of the container tobe able to withstand automotive vehicle processing temperatures (e.g.,e-coat or paint processing oven or bath temperatures as furtherdiscussed herein) without any deformation or any substantialdeformation. However, in another embodiment, the material of thecontainer may be configured to deform or be deformable at suchtemperatures. For example, it is contemplated that the material may beor may become stretchable at such temperatures or other temperatures andexpansion of the expandable material may cause such stretching.

Once the container has been provided, an expandable material ispreferably placed within the container thereby forming a member forbaffling, sealing and/or reinforcing an article of manufacture. As canbe seen in FIG. 2, a plurality of pellets 30 of the expandable materialhas been placed within the open space 16 of the container 12 to formsuch a member 32. Preferably, the pellets 30 are large enough to preventtheir passage through the openings 20 at least while they are in asubstantially solid state. Advantageously, the expandable material isoften supplied in the form of pellets such that further processing ofthe expandable material is not required. Of course, it is contemplatedthat the expandable material may be processed if desired or needed.

In any of the disclosed embodiments, it is contemplated that one or morestructures may be placed within the open space of the container suchthat the expandable material does not need to fill as much space. As anexample, FIG. 4A illustrates a hollow structure 34 such as a plasticcylindrical structure being inserted into a cylindrical container 36.Preferably, pellets 38 of expandable material are arranged to surroundthe structure 34 while in the container 36.

While the expandable material is configured as pellets in FIG. 2, theexpandable material may be placed within any container of the presentinvention in a variety of different configurations. For example, theexpandable material may be provided as a single mass or as multiplemasses and the masses may be identical or non-identical with respect toeach other.

Preferably, the expandable material is a heat activated material havingfoamable characteristics. The material may be generally dry to the touchor tacky and can be placed within or adjacent the container in any formof desired pattern, placement, or thickness. Exemplary expandablematerials include L-5248, L-7002 and L-5204 foams available through L&LProducts, Inc. of Romeo, Mich.

Though other heat activated materials are possible for the expandablematerial, a preferred heat activated material is an expandable plastic,and preferably one that is foamable. Particularly preferred materialsare an epoxy-based and EVA (Ethylene Vinyl Acetate) based structural,sealing, baffling or sound-absorbing foams. For example, and withoutlimitation, the structural foam may be an epoxy-based material,including an ethylene copolymer or terpolymer that may possess analpha-olefin. As a copolymer or terpolymer, the polymer is composed oftwo or three different monomers, i.e., small molecules with highchemical reactivity that are capable of linking up with similarmolecules.

A number of reinforcing, sealing and/or baffling foams are known in theart and may also be used to produce foam. A typical foam includes apolymeric base material, such as an epoxy resin, an ethylene-basedpolymer, an acrylate and/or acetate based material or a combinationthereof which, when compounded with appropriate ingredients (typically ablowing and curing agent), expands and cures in a reliable andpredictable manner upon the application of heat or the occurrence of aparticular ambient condition. From a chemical standpoint for athermally-activated material, the structural foam is usually initiallyprocessed as a flowable thermoplastic material before curing. It willcross-link upon curing, which makes the material incapable of furtherflow.

Examples of preferred foam formulations are EVA based and epoxy-basedmaterials that are commercially available from L&L Products of Romeo,Mich., under the designations L5206, L5207, L5208, L5209, L5218, L5224,L-5248, XP321 and XP721. One advantage of the preferred foam materialsover prior art materials is that the preferred materials can beprocessed in several ways. The preferred materials can be processed byinjection molding, extrusion, compression molding, application with amini-applicator, pelletization of the like. This enables the formationand creation of part designs that exceed the capability of most priorart materials. In one preferred embodiment, the structural foam (in itsuncured state) is generally is dry or relatively free of tack to thetouch.

While the preferred materials for fabricating the expandable materialhave been disclosed, the material can be formed of other materialsprovided that the material selected is heat-activated or otherwiseactivated by an ambient condition (e.g. moisture, pressure, time or thelike) and cures in a predictable and reliable manner under appropriateconditions for the selected application. One such material is the epoxybased resin disclosed in U.S. Pat. No. 6,131,897, the teachings of whichare incorporated herein by reference, filed with the United StatesPatent and Trademark Office on Mar. 8, 1999 by the assignee of thisapplication. Some other possible materials include, but are not limitedto, polyolefin materials, copolymers and terpolymers with at least onemonomer type an alpha-olefin, phenol/formaldehyde materials, phenoxymaterials, and polyurethane materials with high glass transitiontemperatures. See also, U.S. Pat. Nos. 5,766,719; 5,755,486; 5,575,526;and 5,932,680, (incorporated by reference). In general, it is desirablefor the expandable material to have good corrosion resistanceproperties. Still another desirable expandable material, which includesone or more acrylates, one or more acetates or a combination thereof isdisclosed in U.S. provisional patent application Ser. No. 60/482,897filed Jun. 26, 2003, incorporated herein by reference for all purposes.

In applications where the expandable material is a heat activated,thermally expanding material, an important consideration involved withthe selection and formulation of the material comprising the foam is thetemperature at which a material reaction or expansion, and possiblycuring, will take place. For instance, in most applications, it isundesirable for the material to be reactive at room temperature orotherwise at the ambient temperature in a production line environment.More typically, the expandable material becomes reactive at higherprocessing temperatures, such as those encountered in an automobileassembly plant, when the foam is processed along with automobilecomponents at elevated temperatures or at higher applied energy levels,e.g., during painting preparation steps. While temperatures encounteredin an automobile assembly operation may be in the range of about 148.89°C. to 204.44° C. (about 300° F. to 400° F.), body and paint shopapplications are commonly about 93.33° C. (about 200° F.) or higher. Ifneeded, blowing agent activators can be incorporated into thecomposition to cause expansion at different temperatures outside theabove ranges or expansion at different rates or to different degrees.

Generally, suitable expandable foams have a range of expansion rangingfrom approximately 0 to over 1000 percent. The level of expansion of theexpandable material may be increased to as high as 1500 percent or more.In still other embodiments, it is contemplated that the expandablematerial expands to at least 2000%, 2500%, 3000% or more relative to itsoriginal non-expanded size. Typically, strength is obtained fromproducts that possess low expansion while baffling and/or soundabsorption is obtained through greater expansion.

In another embodiment, the expandable material is provided in anencapsulated or partially encapsulated form, which may comprise apellet, which includes an expandable foamable material, encapsulated orpartially encapsulated in an adhesive shell. An example of one suchsystem is disclosed in commonly owned, co-pending U.S. application Ser.No. 09/524,298 (“Expandable Pre-Formed Plug”), hereby incorporated byreference.

In addition, as discussed previously, preformed patterns may also beemployed such as those made by extruding a sheet (having a flat orcontoured surface) and then die cutting it according to a predeterminedconfiguration in accordance with the chosen container or structure, andapplying it thereto.

The skilled artisan will appreciate that the system may be employed incombination with or as a component of a conventional sound blockingbaffle, or a vehicle structural reinforcement system, such as isdisclosed in commonly owned co-pending U.S. application Ser. Nos.09/524,961 or 09/502,686 (hereby incorporated by reference).

Assembly of the member (i.e., the container with the expandablematerial) to a structure typically includes placement and/or securing ofthe member adjacent to the structure. Thereafter, the expandablematerial is activated to expand and, upon expansion, at least a portionof the expandable material travels through the one or more openings ofthe container to contact one or more surfaces or walls of the structure.Upon cooling, the expandable material, now expanded, cures and adheresor attaches the container and the expandable material to the one or moresurfaces or walls.

In FIG. 3, the member 32 has been placed within a cavity 50 defined byone or more walls of an automotive pillar structure 52 to form thesystem 10. In the embodiment shown, the member 32 has been placed in thecavity 50 bottom first such that the top and bottom wall 24, 26 areperpendicular or substantially perpendicular (i.e., within 30°, morepreferably within 20°, and even more preferably within 10° ofperpendicular) relative to the one or more walls of the structure 52. Ofcourse, it is contemplated that one of the side walls 28 or the top wall24 may be inserted in the cavity 50 first such that the member 32 isotherwise arranged in the cavity.

The member 32 illustrated has been secured within the cavity 50 byinterference fitting the container 12 against the walls of the structure52 defining the cavity 50. In alternative embodiments and depending onthe container 12 and structure 52, however, the member 32 may be, atleast temporarily, attached to or adjacent a structure using a varietyof techniques. For example, and without limitation, fasteners (e.g.,screws, rivets, arrowhead fasteners, adhesives, magnets, interferencefit fasteners, hooks, push-pins or others) may be employed to secure themember 32 in a desired location relative to the structure.

Upon activation, the pellets 30 of expandable material expand, combineand travel through the openings 20 to contact the one or more walls ofthe structure 52. Upon cooling, the expandable material adheres to thewalls thereby securing the container and the expandable material withinthe cavity 50. Preferably, the expandable material, the container 12 orboth substantially span the entire cross-section of the cavity 50 toprevent passage of materials therethrough.

While the expandable material has been illustrated as being formed of asubstantially singular substantially homogeneous material, it iscontemplated that various different expandable materials may beemployed. For example, a portion of the open space of the container maybe filled with a relatively high expansion (e.g., at least about 1000%expansion) material and an adjacent portion (e.g., a portion above orbelow the original portion) of the open space of the container may befilled with a lower expansion (e.g., less than 1000% expansion)reinforcing material. Thus, a system may be formed to providesubstantial acoustic damping and substantial reinforcement.

Referring to FIGS. 5A and 5B, there is illustrated another exemplarycontainer 100 suitable for forming a system according to the presentinvention. The container 100 includes a first wall 102 opposing andpreferably substantially parallel to a second wall 104. A peripheralwall 108 extends about the outer perimeters of the first and secondwalls 102, 104 such that the first wall 102, 104 is spaced apart fromthe second wall 104. Preferably, the peripheral wall 108 has a width (W)of between about between about 0.1 cm and about 5 cm, more preferablybetween about 0.3 cm and about 2 cm and even more preferably betweenabout 0.6 cm and about 1.2 cm such that the first wall 102 is spacedfrom the second wall 104 by approximately than width (W). Cooperatively,the first wall 102, the second wall 104 and the peripheral wall 108substantially define an internal open space 114.

In the embodiment shown, each of the walls 102, 104, 108 respectivelyincludes a plurality of openings 118, 120, 122 (e.g., through-holes)extending between the open space 114 and an environment 126 surroundingthe container 100. Preferably, each of the openings 118 of the firstwall 102 are spaced apart from each other by distances of between about0.3 cm and about 10 cm, more preferably between about 0.6 cm and about 5cm and even more preferably between about 0.8 cm and about 2.0 cm. It isalso preferable for each of the openings 120 of the second wall 104 tobe spaced apart from each other by the same distances suggested for theopenings 118 of the first wall 102. The openings 122 of the peripheralwall 122 are preferably spaced apart from each other by distances ofbetween about 0.1 cm and about 5 cm, more preferably between about 0.3cm and about 2 cm and even more preferably between about 0.6 cm andabout 1.2 cm.

The openings 118, 120, 122 preferably have diameters of between about0.1 cm to about 2.0 cm, more preferably between about 0.2 cm and about1.0 cm, and even more preferably between about 0.3 cm and about 0.5 cm.As used herein, the term diameter means, with respect to the pluralityof openings 118, 120, 122, any distance spanning across a largestdimension of an opening extending in a direction substantially parallelwith the wall or member that defines the opening.

The open space 114 is preferably at least partially or substantiallyfilled with the expandable material as described herein. The expandablematerial may be provided as pellets, as a singular piece of material orotherwise as described herein. The expandable material may be locatedwithin the open space 114 by molding the container 100 about theexpandable material or by placement of the material in the open space114 after formation of the container 100 (e.g., where the container 100is made of two or more parts, which can be fastened together).

For forming a system (e.g., a baffling system) according to the presentinvention, the container 100 and expandable material are placed in acavity of a structure (e.g., a pillar structure) in a manner similar tothat described in relation to the container 12 of FIGS. 1-4 (e.g.,interference fit or fastened). The container 100 of FIGS. 5A and 5B, ispreferably placed in a structure such that the peripheral wall 108opposes and corresponds to walls of the structure. Thus, upon activationof the expandable material, the expandable material expands and flowsthrough the openings 122 of the peripheral wall 108 to contact the wallsof the structure. Upon curing, the expandable material preferablyadheres the container 100 in place to the walls of the structure. It isalso preferable that the expandable material flows through the openings118, 120 of the first and second walls 102, 104 for forming a foamcoating over the outer surface of one or both of the walls 102, 104.

Referring to FIGS. 6A and 6B, there is illustrated an alternativecontainer 130 having a similar configuration to the container 100 ofFIGS. 5A and 5B. The container 130 includes a peripheral wall 134substantially identical to the peripheral wall 108 of FIGS. 5A and 5B.The peripheral wall 134 along with a first wall 136, a second wall 138and an internal wall 140 form a peripheral tubular structure 146. Theperipheral wall 134, and the first and second walls 136, 138respectively include openings 150, 152, 154 that are arranged and sizedin a manner substantially identical to that described for the peripheralwall 108 and the first and second walls 102, 104 of the container 100 ofFIGS. 5A and 5B.

A spanning wall 160 substantially continuously spans an area internal ofthe tubular structure 146 wherein the area and the wall 160 aresubstantially surrounded by the tubular structure 146. Of course, thespanning wall 160 may be discontinuous as it spans the area as well andthe tubular structure 146 may only partially surround the spanning wall160.

Expandable material my be located in the open space 148 of the container130 and the container 130 of FIGS. 6A and 6B may be placed within astructure in the same manner as described with respect to the container100 of FIGS. 5A and 5B and the expandable material may be activated toexpand and flow to adhere the material and the container 130 in place ina manner substantially identical to that described for the container 100of FIGS. 5A and 5B. It should be noted that additional expandablematerial may be located upon the spanning wall 160 of the container 130for providing increased baffling or sound absorption.

Referring to FIG. 7, there is illustrated still another alternativeembodiment of the present invention. As shown, a container 170 is formedof a porous fabric or flexible material (e.g., a permeable fabric, amesh fabric, a perforated fabric or the like) that substantiallysurrounds pellets 174 of expandable material. A fastener 178 (e.g., athreaded fastener, a mechanical interlock fastener or the like) isattached to the container 170. Preferably, the fastener 178 is extendedthrough the porous container such that the fastener assists inmaintaining the container surround the plurality of pellets.

For forming a system according to the present invention, the container170 with the pellets 174 is held in place with the fastener 178 within acavity of a structure. In such and embodiment, the fastener 178 may beattached directly to the structure or may be attached to othercomponents of an article of manufacture (e.g., an automotive vehicle).In turn, the expandable material may be activated to expand and flowthrough openings 182 of the container 170 to contact and wet walls ofthe structure. Upon curing, the expandable material adheres itself andthe container 170 to the walls of the structure. Preferably, theexpandable material and the container 170 seal the cavity of thestructure against passage of materials therethrough and/or provide sounddampening of baffling within the structure.

Generally, for the various embodiments of the present invention, thewalls or materials of the containers, and particularly the walls ormaterials having the openings, will have a relatively largetransmittance for allowing easier flow of the expandable materialthrough the opening. As used herein, the term transmittance refers tothe size of the openings relative to the size of the walls or materialsof the containers defining those walls. In particular, the transmittancepercentage is the amount of area through which the openings will allowpassage of expandable material therethrough as opposed to the amount ofarea of the wall or material that blocks the expandable material. Thus,for example, a wall in a plane with opening extending through 50% of thewall would have a 50% transmittance. Typically, the walls or materialsof the present invention will allow for at least 40% transmittance, moretypically at least 60% transmittance, even more typically at least 80%transmittance and still more typically at least 90% transmittance.

The actual openings for the container can be relatively small orrelatively large to provide relatively small or large pass-throughareas. As used herein, pass-through areas are the smallest planar areasof the openings, as entirely defined by the container, through which theexpandable material can pass. Exemplary pass through area are typicallyat least 1 mm² or less, more typically at least 3 mm² and even moretypically at least 5 mm² and are typically less than 10 cm², moretypically less than 5 cm² and even more typically less than 2 cm².

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A method for sealing, baffling or reinforcing, comprising: providinga rigid polymeric porous container, the porous container having an upperwall and a lower wall and one or more side walls extending about theouter perimeter of the upper wall and the lower wall, the one or moreside walls providing a plurality of openings such that the one or moreside walls have a transmittance percentage of at least 60%, the openingsbeing configured so that upon being heated and during expansion anexpandable material flows through the openings; containing theexpandable material within the porous container in the internal openspace, the expandable material being provided as a plurality of pellets,the pellets being large enough to prevent passage through the pluralityof openings while substantially in a solid state prior to expansion, thecontainer having a closable opening for receiving the plurality ofpellets and thereby surrounding the plurality of pellets; locating theporous container and the expandable material within a cavity of astructure of an automotive vehicle; activating the pellets of expandablematerial such that at least a portion of the material expands and flowsduring expansion through the one or more openings, combine with otherpellets and contacts and adheres to walls of the structure.
 2. A methodas in claim 1 wherein the expandable material is substantially entirelycontained within the porous container prior to expansion thereof.
 3. Amethod as in claim 1 wherein the expandable material expands over 500%relative to its original non-expanded size.
 4. A method as in claim 1wherein the expandable material expands over 1000% relative to itsoriginal non-expanded size.
 5. A method as in claim 1 wherein theexpandable material expands over 2000% relative to its originalnon-expanded size.
 6. A method as in claim 1 wherein the expandablematerial is thermosettable and is activated to expand and thermoset at atemperature encounter in an e-coat or paint oven.
 7. A method as inclaim 1 wherein the upper wall is at least partially defined by a lidfor creating the closable opening.
 8. A method as in claim 7 wherein thecontainer is formed of molded nylon.
 9. A method as in claim 8 whereinthe one or more side walls include an annular wall.
 10. A method as inclaim 1 wherein the pellets of expandable material are derived fromvarious different expandable materials.
 11. A method as in claim 1wherein the plurality of openings in the one or more side walls are lessthan 2 cm².
 12. A method for sealing, baffling or reinforcing,comprising: providing a porous container, the porous container providingone or more openings, wherein: i) the porous container is formed of arigid polymeric material and defines an internal open space; ii) theporous container includes a substantially continuous non-porous upperwall opposing a substantially continuous non-porous lower wall; iii) theporous container includes one or more side walls extending between theupper wall and the lower wall; iv) a plurality of openings are definedin the one or more side walls for providing fluid communication betweenthe internal open space and any environment surround the container; andv) the one or more side walls have a transmittance percentage of atleast 60%, the openings being configured so that upon being heated andduring expansion the expandable material flows through the openings;containing the expandable material within the porous container in theinternal open space, wherein: i) the expandable material is provided asa plurality of pellets, the pellets being large enough to preventpassage through the openings while substantially in a solid state priorto expansion; ii) the porous container substantially surrounds theplurality of pellets; and locating the porous container and theexpandable material within a cavity of a structure of an automotivevehicle; activating the pellets of expandable material such that atleast a portion of the material flows through the one or more openings,combine with other pellets and contacts and adheres to walls of thestructure wherein: i) the container and the expandable materialcooperatively substantially span and seal of the cavity of the structureof the automotive vehicle.
 13. A method as in claim 12 wherein theexpandable material expands over 2000% relative to its originalnon-expanded size.
 14. A method as in claim 12 wherein the expandablematerial is thermosettable and is activated to expand and thermoset at atemperature encounter in an e-coat or paint oven.
 15. A method as inclaim 12 wherein the upper wall is at least partially defined by a lid.16. A method as in claim 12 wherein the container is formed of moldednylon.
 17. A method as in claim 12 wherein the one or more side wallsinclude an annular wall.
 18. A method as in claim 12 wherein the pelletsof expandable material are derived from various different expandablematerials.
 19. A method as in claim 12 wherein the plurality of openingsin the one or more side walls are less than 2 cm².